SERVICE

Deutschland Italien
CompAir Drucklufttechnik GmbH CompAir Italia S.r.l.
Zentral-Ersatzteildienst Aria Compressa
Argenthaler Straße 11 Via Archimede 31
D-55469 Simmern/Hunsrück I-20041 Agrate Brianza (Mi)
Postfach 169 Telefono ++ 39 / 0 39 / 6 55 11
D-55461 Simmern/Hunsrück Telefax ++ 39 / 0 39 / 6 05 64 58
Telefon Inland 0 67 61 / 83 21 37 – 40 Telegrammi: CompAir DEMAG - Agrate Brianza
Telefon Ausland (0) 67 61 / 83 21 41 + 42 E-Mail: compair @compair.it
Telex 426 422 Internet: www.ariacompressa.it/compair
Österreich Frankreich
CompAir AGRE GmbH CompAir France S.A.
A-4451 Garsten-St. Ulrich Siège administratif et commercial
Werkstraße 1 31, rue de la Justice
Telefon (0) 72 52 / 5 23 41 - 0
Telefax (0) 72 52 / 5 21 33
Z.I. Vaux le Pénil
B. P. 1939 SC 70 D-1
A-1233 Wien F-77019 Melun Cedex
Gatterederstraße 20 Téléphone ++ 33 (0) 1 64 87 72 20
Telefon (0) 1 / 8 88 25 01 Télécopie ++ 33 (0) 1 64 87 72 21
Telefax (0) 1 / 8 89 17 24 E-Mail: [email protected]
A-5020 Salzburg
Vogelweiderstraße 50 Südafrika
Telefon (0) 6 62 / 87 24 11 CompAir DEMAG Division
SC7
70D-1
Telefax (0) 6 62 / 87 24 11 - 22 CompAir SA (Pty) Limited

20/02-99/D/CH/CU
E-Mail: [email protected] Berrange Road 2 55
Private Bag X029
Großbritannien Wadeville 14 22
CompAir Holman Limited South Africa
Holman Works, Camborne Telephone (0) 11 / 3 45 23 99
Cornwall TR14 8DS, UK Telefax (0) 11 / 3 45 22 04
Telephone (0) 12 09 22 11 00
Telefax (0) 12 09 71 39 55 Belgien
CompAir n.v.
Spanien Grensstraat 2
CompAir Holman Iberica SA B-1831 Diegem
Ctra. de Andalucia Km. 18 Telephone ++ 32 (2) 7 20 48 90
28320 Pinto (Madrid) Telefax ++ 32 (2) 7 21 17 60
Aptdo. 14.785-28080 E-Mail: [email protected] Operating Manual:
Teléfono ++ 34 (91) 6 49 92 00
Telefax ++ 34 (91) 6 49 92 44 Fachhändler Screw Compressor
E-Mail: [email protected]

DIN ISO 9001 /

EN 29001 Ident-Nr. 133 920 74/01 BA 145/GB (02/97)
Zertifikat: 5168
Schutzgebühr DM 10.- / $ 6.- / FFr 36.-
 1. Foreword

1.1 Information on the compressor 1.2 Normal use

CompAir DEMAG screw compressors The compressors have been built using
are the product of many years' research the latest techniques in design and in
and development. These preconditions, accordance with recognized safety
together with high quality standards, regulations.
guarantee the manufacture of screw
Nevertheless, the operator or third parties
compressors with a long service life, a high
may be exposed to risk to life and limb in
degree of reliability and cost-effective
the course of the use of the compressor
operation. The strict environmental
(e.g. through flying pieces of building
protection standards have of course been
material, swirling particles of dirt or dust,
complied with.
electrical current, thermal vibrations, noise
or mechanical hazards), and the machine
or other tangible assets may be impaired,
for reasons that could not have been
avoided through preventive constructional
safety measures.
Hazards occur particularly when:
* The compressor is not used for its
intended purpose
* The compressor is not operated by
trained personnel
* Unauthorized changes or modifications
are carried out on the compressor
* You are not wearing the prescribed
protective clothing
* You do not comply with the safety
instructions
* You do not observe the information in
the operating manual
For this reason every person involved
in the operation, maintenance and repair
of the compressor must read and observe
the operation manual and the safety
regulations. This is to be confirmed by
signature as required.

1
 1. Foreword 10. Troubleshooting

Furthermore, the following naturally apply: 1.3 Specifications Problem Possible cause(s) Correction
* The relevant accident prevention Oil comes out of the air Intake regulation valve Check and repair
regulations Compressor type SC 70 D-1 filter of the compressor defective
Delivery volume . . . . . . . . . 6.9 m3/min after the screw compressor
* Generally recognized safety and traffic has been shut down
regulations Operating pressure . . . . . . 7 bars
Pressure range . . . . . . . . . 5 - 8 bars
* Particular national regulations Oil fill (screw compressor) . 27 l Engine starts but switches V-belt defective Replace
Engine . . . . . . . . . . . . . . . . F4L912 KHD off again immediately, or the
The compressor is designed for providing Oil pressure switch/engine Replace
Type of cooling . . . . . . . . . Air system switches off while
compressed air: defective
Engine power . . . . . . . . . . 54.5 kW running
* For operating compressed-air Vee belt switch defective Replace
Speed range . . . . . . . . . . . 1250-2500 rpm
appliances Oil fill (engine) . . . . . . . . . . 10 l Compressor temperature Replace
Fuel tank capacity . . . . . . . 90 l switch defective
* For conveying bulk material
Gross vehicle weight rating 1500 kg Compressor defective
* For conveying flooring plaster Operating weight (approx.) 1250 kg
Length (max.) . . . . . . . . . . 3690 mm Cable of safety system Replace or plug onto sensor
* For sandblasting and paint-spraying defective or cable cover not
operations Width . . . . . . . . . . . . . . . . . 1700 mm
Height . . . . . . . . . . . . . . . . 1540 mm plugged onto sensor
* For cleaning machines and shuttering Rim . . . . . . . . . . . . . . . . . . 5 1/2 J x 14 Relay defective Replace
material - do not direct towards persons! Tyres . . . . . . . . . . . . . . . . . 185 R 14 C
Solenoid valve defective Replace
* For blow-cleaning drilled holes. Tyre pressure . . . . . . . . . . 3.25 bars
Compressed air connections 3 x R 3/4" Ignition and starting switch Replace
Any other use, or any additional use, fuse or diode defective
for example as respiratory air, is regarded
Generator defective Repair or replace
as not being for the originally intended
purpose. The manufacturer / supplier Generator controller Repair or replace
accepts no liability for any resulting defective
damage. The risk is assumed by the user Other engine problems See engine operating
alone. manual
The compressor may only be used in
a technically perfect condition, for its
intended purpose, with appropriate
awareness of safety regulations and
hazards, subject to compliance with the
operating manual. In particular, faults
representing safety hazards are to be
corrected at once.

2 63
 10. Troubleshooting 1. Foreword

Problem Possible cause(s) Correction 1.4 Maintenance and care If you have important questions,
Screw compressor will not No fuel Fill up with fuel
start Care and maintenance are all-important
Fuel filter clogged Replace fuel filter cartridge if the screw compressor is to meet the CompAir Drucklufttechnik GmbH
Fuel line loose, broken, or Repair line demands placed upon it. Compliance with Werk 55469 Simmern

jammed the prescribed maintenance intervals and

careful execution of care and maintenance
Operating voltage low Charge battery or replace
work are therefore essential, especially
Electrical connection loose, Replace under difficult working conditions.
corroded, or broken
Air in system Extend starting operation Typ, type, modèle, tipo

(automatic ventilation) Service 1 2

Handelsbezeichnung, trade name, dénomination Baujahr, year,

commerciale, denominazione commerciale année, anno

Solenoid valve out of order Replace In case of faults, or should you require 3 4

spare parts for the screw compressor, Auftrags-Nr., order number,

5
Relay defective Replace please contact your local CompAir DEMAG
numéro de commande, numero d'ordine

max. Stützlast an Kupplung, max. tongue load at

coupling, charge d'appui à l'attelage,
6 N
Starter defective Replace agent. carico di appoggio massimo sulla frizione

Volumenstrom, flow rate

flux volumique, flusso volumetrico 7 m3/min

Other engine problems See engine operating manual In case of damage, the trained technical Ansaugdruck, intake pressure,
pression d'aspiration, pressione d'aspirazione 8 bar

Fuse defective Replace staff will guarantee a fast, expert repair Stufendrücke, stages pressures,
9 bar
pression d'etages, pressioni degli stadi di compressione
using CompAir DEMAG spare parts.
Ignition and starting switch Replace Original CompAir DEMAG spare parts are
Drehzahl, revolutions per minute,
régime de rotation, numero dei giri 10 min-1

defective manufactured according to the state of

Installierte Motorleistung, installed engine power,
puissance moteur installée, pressione di aspirazione
11 kW

Diode defective Replace the art and guarantee continued reliable

operation. Fig. 2
Oil in air line Orifice in oil return line Repair / clean
Please enter the data from the identifi-
clogged
cation plate for your compressor, in the
Oil fine separator defective Replace spaces above (fig. 2). In case of questions
Too much oil in pressure tank Correct or orders for spare parts, please give us
the compressor type, compressor number
Safety valve blows off Controller set too high Set and the year of construction as given on
the identification plate.
Pressure control valve Replace or repair
defective If you give us this data you can be sure that
you will be given the correct information or
Intake control valve, control Replace sent the spare parts you require.
cylinder, engine, or connected
control lines defective
Safety valve defective Replace

62 3
 1. Foreword 10. Troubleshooting

1.5 General information Warranty Problem Possible cause(s) Correction

Only use this compressor with accurate Insufficient or no air supply Clogged air filter screw Clean air filter
This operating manual is to help you to knowledge of and in compliance with this compressor
get to know the compressor and to use it manual.
for its intended applications. It contains Engine speed misadjusted Set speed
important information about how to operate CompAir Drucklufttechnik GmbH do not Clogged oil fine separator Replace compressor oil,
the compressor safely, cost-effectively accept responsibility for safe functioning of filter cartridge oil filter and oil fine
and with due care. Compliance with the the compressor for actions that do not separator filter cartridge
instructions in this manual will help to avoid correspond to normal use or for purposes
not mentioned in the manual. Wrong setting at controller Adjust
danger, reduce repair costs and downtime,
and increase the reliability and service life Butterfly in intake control Clean, replace parts if
Warranty claims cannot be entertained for:
of the compressor. valve not fully opened necessary, readjust
* Operating errors
This operating manual is to be Insufficient pressure Pressure control valve Repair or replace
supplemented by instructions concerning * Inadequate maintenance
defective
current national regulations for accident * Incorrect fuels
prevention and environmental protection. It Control line defective Repair or replace
must always be available at the site of the * Damage caused by non-use of original Piston ring or spring in Replace
compressor. The operating manual is to be CompAir DEMAG parts engine control cylinder or
read and used by all persons in charge of controller defective
* Modification of the system.
work with the compressor, for example
operation, including setting up, correcting The Guarantee and Liability terms of Pressure control valve Pressure controller set too Set
faults during operation, disposal of waste CompAir Drucklufttechnik GmbH's General blows off hard at idling high
products from production, care, disposal of Terms and Conditions are not extended speed
process materials, upkeep (maintenance, through the above instructions. Intake control valve Replace or repair
inspection, repair) and transport. defective
Any unauthorized modification of the
Control line loose, broken, Repair
Besides the operating instructions and compressor system/station or the
or jammed
the current regulations applicable in the installation of components (e.g. fine
user's country and at the sites of operation separators) not released by the Pressure control valve Replace
concerning accident prevention, the manufacturer result in the loss of the CE defective
recognized technical rules for safe and symbol.
proper working are also to be complied Compressor becomes Wrong oil Replace
This fact results in the termination/
with. excessively hot
expiration of the guarantee and warranty Compressor oil level too low Fill up with oil
(automatic shutdown)
claims against the manufacturer. Fan broken Replace
Oil cooler dirty (outside) Clean
Oil filter clogged Replace
Leak in oil line Repair or replace
Air short circuit Repair

4 61
 9. Maintenance 1. Foreword

9.4.10 Torque specifications Safety regulations

The following torque specifications apply to Danger

the bolted connections:
It is important that you follow the safety
Wheel bolts M12 x 1.5 spherical 90 Nm regulations in Chapter 3 of the operating
manual.
Pressure vessel cover 40 Nm
Safety valve 50 Nm
Technical modifications
Motor support
M12 8.8 78 Nm We reserve the right to undertake
M16 8.8 180 Nm modifications without notice in the interests
of technical progress.
Compressor support M12 12.9 169 Nm
Trailer fixing bolt M12 8.8 78 Nm
Suspension 47 Nm

60 5
 2. Index 9. Maintenance

1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9.4.7 Control 9.4.9 Battery maintenance

1.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Security regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Identification of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Modifications and alterations to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fig. 27 Fig. 28
3.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 The control is designed as continuous Danger
3.7 Instructions concerning particular hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 speed control consisting of:
3.8 Symbols and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 * The intake control valve on the air intake The gases released by the battery are
explosive.
4. Construction and functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 * The control cylinder motor
Avoid sparks and open fires in the
4.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 * The controller vicinity of the battery.
4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 The intake control valve contains a cone, Do not allow acids to come into contact
4.3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 which changes the volume of the air intake with skin or clothing. Wear safety
4.4 Wiring Diagram - Basic Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 and which has a non-return function, in goggles.
4.5 Terminal Diagram DIN ISO 1724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 order to prevent the intake control valve
and the air filter from being flooded with oil Place no tools on the battery.
5. Transport and installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 when the screw compressor is turned off. The battery is maintenance-free in
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 accordance with DIN.
5.2 Loading / Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 9.4.8 Setting engine speed Attention

Check the acid level after a maximum

6. Preparing the compressor for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Attention of 1,000 operating hours, or after
6.1 Checking oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 24 months, whichever occurs first, and
Full load speed is factory-set by the fill up with distilled water if necessary.
6.1.1 Checking the oil level in the pressure tank . . . . . . . . . . . . . . . . . . . . . . . . . . 41
manufacturer and must not be modified.
6.1.2 Checking the oil level in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
For battery maintenance please also
6.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
refer to the manufacturer’s instructions and
6.3 Filling up the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
the engine operating manual.
6.4 Checking the air filter maintenance display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6 59
 9. Maintenance 2. Index

Maintenance of the air filter 9.4.6 Checking the safety valve 7. Putting the compressor into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Note 7.1 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Check air filter for dust at least once per 7.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
week. 7.4 Setting the operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
The maintenance intervals are dependent 7.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
on the prevailing dust conditions. 7.7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removing the filter cartridge: 7.8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
* Loosen the tensioning brackets at the air 8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
filter and fold away.
8.1 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
* Remove filter hood.
8.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
* Remove filter cartridge from the filter Fig. 26 8.3 Tool lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
hood. 8.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
* Replace filter cartridge.
Danger
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Danger The safety valve must be checked for
proper operation before each run. 9.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve cone may be moved to open by 9.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Never clean the air filter cartridge with
turning knob. 9.3 Maintenance of chassis and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
inflammable liquids.
9.4 Compressor maintenance / Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 53
If the safety valve does not work 9.4.1 Oil filter replacement (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Reassembling the air filter: properly, it must be replaced 9.4.2 Oil change (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
* Clean the sealing surface in the filter immediately by a new safety valve 9.4.3 Checking the automatic monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . 56
housing. designed for the required pressure. 9.4.4 Inspecting / Replacing the fine separator . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.4.5 Air filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
* Insert the filter cartridge and make sure Attention 9.4.6 Checking the safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
that the seal is properly seated.
9.4.7 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
The screw compressor must not be
* Replace filter hood and fasten using the 9.4.8 Setting engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
operated with a defective safety valve.
tensioning brackets. 9.4.9 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.4.10 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

58 7
 3. Security Regulations 9. Maintenance

3.1 Identification of safety 3.2 General safety instructions Replace the fine separator at least once 9.4.5 Air filter replacement
per year or measure the differential
instructions
Organizational measures pressure as follows:
Danger
CompAir DEMAG accepts no Please keep this operating manual handy * When the engine is at a standstill and
responsibility for any damage or injury at all times on the site of the machine / the screw compressor is not under All inspections and servicing work must
caused by non-compliance with these installation, in the bag provided. pressure, unscrew the dipstick from the be carried out when the engine is at a
safety measures or non-observance of pressure tank. standstill and the screw compressor is
normal care and caution during the Please note and pass on general not under pressure.
handling, operation, maintenance or statutory and other binding regulations * Screw in the reducing adapter.
repair of this compressor, even if not that may supplement the operating * Screw the pressure gauge into the
expressly stated in this operating manual. manual for the prevention of accidents reducing adapter, Air filter replacement -
and the protection of the environment. Screw compressor and engine
If any of the regulations contained in Such obligations may be for example the * Start the screw compressor.
this manual do not correspond to local handling of hazardous materials, or the
statutory provisions, particularly with * The difference in pressure between the
provision and/or wearing of personal pressure gauge on the pressure tank
reference to safety, then the stricter of protective equipment, or traffic regulations.
the two applies. and the pressure gauge on the
Instructions, including supervisory instrument panel must not exceed 1 bar.
These safety instructions are of a general responsibility and duty of notification for
nature and are applicable to various types taking account of special in-plant factors,
of machine and equipment. For this reason for example regarding work organization, If the differential pressure is > 1 bar, the
it is possible that some information may not sequences of operations, personnel fine separator cartridge must be replaced.
apply to the aggregate(s) described in this assigned to certain tasks, are to be added
manual. * Disconnect all lines from the tank cover.
to the operating manual.
* Unscrew all hexagonal bolts on the
Personnel delegated to work with the cover circumference.
machine must have read the operating Fig. 25
Danger
manual before beginning this work, * Take off the cover and remove the used
particularly the chapter on safety fine separator. Note
Places thus marked refer to possible
dangers for persons. instructions. It is too late to do this while
* Remove the used seals from the Replace the air filter of the screw
working. This applies particularly to
pressure tank, clean the sealing surface compressor and engine once yearly (but at
Attention personnel only using the machine
and insert new seals. least every 250 hours).
occasionally, e.g. for setting up and
Places thus marked refer to possible maintaining the machine. * Insert new fine separator in the pressure Observe the maintenance indicator. Do not
dangers for machines or parts of tank and insert new seals. clean or reuse the air filters.
Safety and danger-conscious working
machines.
by the personnel in compliance with the * Replace cover, insert hexagonal bolts Replace air filter.
Note operating manual should be checked at and tighten them in crisscross pattern.
* Loosen retaining clip.
least occasionally.
* Reconnect all lines to the tank cover. * Remove used air filter.
Places thus marked give general and * Insert new air filter.
technical information for optimum, cost- * Check for leaks.
* Tighten retaining clip.
effective machine use. * Dispose of used fine separator in
accordance with the relevant
regulations.

8 57
 9. Maintenance 3. Security Regulations

9.4.3 Checking the automatic 9.4.4 Inspecting / Replacing the fine The personnel must not have long, loose Personnel selection and qualification;
hair, or wear loose clothing or jewellery, basic tasks
monitoring system separator
including rings, due to risk of injury through
Work on or with the machine / installation
catching. Personal protective equipment
Danger may only be carried out by reliable
should be worn if necessary or as required
personnel. Observe the minimum statutory
by regulations.
Caution! High voltage! The sensors of age.
the automatic monitoring system must Pay attention to all safety and danger
Only trained or specially instructed
not be short circuited. warnings on the machine/ installation!
personnel may be assigned to this work.
Check individually every 1,000 operating Make sure that all safety and danger The responsibility of the personnel for
hours: warnings on the machine / installation can operating, setting up, maintaining and
be read. repairing the machine / installation must
1. Temperature sensor - screw compressor
be clearly defined.
(pressure connection) For all safety-relevant modifications to
the machine / installation or its operating Make sure that only authorized personnel
2. Oil pressure switch - engine
behavior, stop the machine / installation use the machine.
3. Motor temperature switch Fig. 24 immediately and report the fault to the
Define who is responsible for operating
competent authority / person.
Danger the machine, and authorize him to ignore
Spare parts must meet the technical instructions from third parties if these
Checking the automatic monitoring system:
Pressure tank is under pressure. Only requirements laid down by the instructions could compromise safety.
* Disconnect connecting cable. work when the motor is at a standstill manufacturer. This is always guaranteed
Only allow personnel that are training,
and the screw compressor is not under when original spare parts are used.
* Connect to ground at temperature that are under instruction or are attending
pressure.
switch. Replace hydraulic hoses at the given a course of general training to use the
Caution with hot oil: risk of scalding! intervals, or at suitable intervals, even if machine / installation under the constant
* Start screw compressor. Spill no oil! no safety-relevant defects are visible. supervision of an experienced person.
* The automatic monitoring system must
Note Observe the intervals stipulated or those Work on the electrical systems of the
switch off the screw compressor
given in the operating manual for routine machine / installation may only be carried
immediately after starting, and the
Dispose of fine separator in accordance checks and inspections. out by a trained electrician in accordance
“Fault” indicator lamp must come on.
with the relevant regulations - hazardous with electrical regulations.
Workshop equipment suitable for carrying
waste! out maintenance work is essential. Only persons with special knowledge and
Check for leaks. experience of hydraulics may work on
The location and operation of fire
system elements, for example components
extinguishers must be made known.
under pressure.
Observe the instructions concerning fire
alarm and firefighting.
Limiting values (pressure, temperature,
time settings etc.) must be permanently
marked.

56 9
 3. Security Regulations 9. Maintenance

3.3 Modifications and alterations 3.4 Loading / Relocation / Transport 9.4.2 Oil change (compressor) Changing the oil:
to the machine * Unscrew dipstick
Loading / Relocation
No alterations, additions, or modifications * Place oil drain pan under oil drain valve
All loose parts that could fall down when
to the machine may be carried out without the machine is lifted must first be removed * Unscrew the sealing cap of the oil drain
the approval of the manufacturer. This or secured; pivoting parts like doors, etc. valve
is also true for the installation and the must be immobilized.
adjustment of safety devices and valves * Collect used oil in the oil drain pan
as well as for welding at supporting For lifting heavy parts, hoisting gear and * When the used oil has been drained
and pressurized parts. Unauthorized heavy-lift facilities with the appropriate completely, use a new sealing ring on
modifications to the machine are prohibited capacities, which have been checked and the sealing screw of the pressure vessel,
for reasons of safety. approved in accordance with local safety position and tighten screw or close the
regulations, must be used. oil drain valve
Original parts are specially designed for
our machines. We must explicitly point out For lifting machines or parts of machines * Fill up with new oil (see section
Fig. 23
that parts and special accessories not with one or more lifting eyes, only hooks "Specifications" in chapter 1 for initial
supplied by us are not approved by us. or shackles complying with local safety Danger oil capacity; use a little less oil when
Installing or using such products may thus regulations may be used. Never fasten performing an oil change).
adversely affect active and/or passive cables, chains or ropes to or through lifting Only change the oil when the engine is
safety. eyes. at a standstill and the screw compressor * For lubricants see “Lubricant Table”

The manufacturer accepts no liability Lifting hooks, lifting eyes, shackles etc. is not under pressure. * Check sealing ring on dipstick, replace if
whatsoever for damage resulting from the must never be bent and must always be Caution when draining off hot oil: necessary
use of non-original parts or special stressed in alignment with the load-carrying risk of scalding! Spill no oil! * Screw in and tighten dipstick
accessories. This also applies to the axis. The load capacity of the hoisting gear
installation and adjustment of safety is reduced if the lifting force is applied at an Attention * Start screw compressor, run for approx.
devices and valves as well as to welding angle to the axis. two minutes, check for leaks
on bearing and pressurized parts. Change the oil filter every 1,000
All bearing parts must be stressed * Switch off screw compressor
operating hours, but at least once per
vertically, as far as possible, for maximum
Note year. * Check oil level, add oil if necessary
safety and optimum performance of the
The General Type Approval becomes hoisting gear. If required, a support is to be The screw compressor must not be
invalid in case of modifications or installed between the hoisting gear and the under pressure during oil change.
alterations which change or infringe load. Secure the load properly.
Drain the oil at operating temperature.
upon the external geometry as well as When heavy loads are being conveyed by
the gross axle weight rating. Do not mix oils of different
means of hoisting gear, it is imperative to
specifications.
keep well clear of the load in order to avoid
accidents. Note
Collect used oil, do not allow it to enter the
soil. Dispose of oil in accordance with the
relevant regulations - hazardous waste!
Spill no oil!
Check for leaks.

10 55
 9. Maintenance 3. Security Regulations

9.4.1 Oil filter replacement Changing the oil filter: Never leave the load suspended on the Transporting the complete unit
hoisting gear.
(compressor) * Unscrew the oil filter cartridge using Make sure that the air vessel is not under
appropriate tools Acceleration or braking of the means of pressure.
transport must remain within the approved
* Dispose of oil filter cartridge Lift and secure supporting gear.
limits.
* Apply a thin coat of oil to the seal of the Make sure that the drawbar eye can
The hoisting gear is to be set up in such
new oil filter cartridge move freely in the tow bar.
a way that the object is lifted vertically.
* Screw on and tighten the new oil filter Should this not be possible, precautions Check to make sure that the drawbar is
cartridge (follow the instructions on the must be taken to prevent the load from adjusted to the bar height of the towing
oil filter cartridge) swinging. Thus it is possible to use two vehicle.
sets of hoisting gear, both with an angle of
* Check for leaks Check to make sure that the body is
inclination of not more than 30° to the
closed and locked, and that the cable for
* Check oil level, add oil if necessary vertical.
the rapid-emergency brake is connected
Nominate experienced supervisors for the to the towing vehicle.
Fig. 22 lifting process.
Join up the connections of the air brake,
Danger Machines may only be hoisted correctly if present.
using hoisting gear in accordance with the
Only replace the oil filter cartridge when Check to make sure that the wheels are
information in the operating manual (limit
the engine is at a standstill and the properly tightened, that the tyres are in a
stop points for heavy-lift facilities etc.)
screw compressor is not under roadworthy condition, that the tyre pressure
Only use a suitable transport vehicle with is correct and that the brakes function
pressure.
sufficient carrying capacity. properly.
Caution with hot oil: risk of scalding!
Before or immediately after completion Connect the cable for the signalling
Spill no oil! of loading, secure the machine / installation and lighting fittings. Check the proper
to prevent accidental shifting. Display an functioning of the lighting.
Attention appropriate warning. Before putting the
Release the handbrake.
machine / installation back into operation,
Change the oil filter every 1,000 the securing devices must be duly Before transporting the unit, always check
operating hours, but at least once per removed. to make sure that the accessories are
year. firmly attached so that they can cause no
Parts to be removed for transport
accidents!
Note purposes must be carefully refitted and
fixed again before putting the machine / When using public roads, tracks and
Dispose of oil filter cartridge in accordance installation back into operation. spaces, observe the current traffic
with the relevant regulations - hazardous regulations, and if necessary make the
When putting the machine / installation
waste! unit roadworthy first!
back into operation again, only proceed in
Check for leaks. accordance with the operating manual.

54 11
 3. Security Regulations 9. Maintenance

Never exceed the maximum towing 3.5 Installation on site / Starting / 9.4 Compressor maintenance / W7 Control (adjustment/function) and
speed. Observe national regulations! solenoid valves
Normal operation Maintenance schedule
Always switch on lights if visibility is poor W8 Check retaining bolts and nuts for
and during lighting-up time! Installation on site Attention the first time after 60 hours, tighten
if necessary (chassis, body), the
When going through underpasses, Besides the general technical operation in
The first oil change of the compressor is correct condition of the suspension
bridges, tunnels, overhead power lines, accordance with the regulations of the local
after 50 operating hours (W1, W2). arrangement must be checked
etc., always make sure that you have authorities, it is essential that the following
every 1000 hours or once annually
enough clearance! guidelines be observed. In your own interest, tick the maintenance
work carried out by you in the maintenance Danger
Always keep a safe distance from the Before switching on the machine /
schedule:
edges of foundation ditches and installation, or starting it up, make sure
The warning sign “Attention!
embankments! that nobody can be injured by the W1 Replace oil filter (screw compressor)
Maintenance work” must be put up
machine / installation as it starts up. every 1,000 hours or once yearly
Do not travel across slopes transversely: before starting to work. Close off the
always keep equipment and loads near The installation is to be set up in such a W2 Oil change (screw compressor) every complete maintenance area, if required.
ground level (for example, do not place way that it is adequately accessible and 1,000 hours or once yearly
them on the bodywork). that the necessary cooling is ensured. W3 Check automatic monitoring, every
Attention
Never block the admission of air. 1,000 hours or once yearly
On descents, always adapt speed to the * Maintenance, general: at regular
circumstances! Never change into low gear The air intake is to be designed in such W4 Check/replace fine separator, once yearly intervals
during the descent, but always beforehand. a way that no dangerous admixtures or if the differential pressure is > 1 bar
(inflammable solvent vapors etc., but * Maintenance, engine: in accordance
When leaving the driver's seat, always W5 Air filter (screw compressor)
also dust and other dangerous or toxic with engine operating manual
secure the unit to make sure that it cannot every 250 hours.
roll away or be used without authorization! substances) can be taken in. This also * Chassis maintenance: in accordance
applies to flying sparks. W6 Check safety valve each time before with chassis instruction manual.
Avoid all operations that adversely affect starting up
the stability of the unit. The air intake is to be designed in such a
way that no loose personal clothing can be
drawn in. Maintenance schedule
Make sure that the compressed air line No. of
from the compressor to the air network can operating 1000 2000 3000 4000 5000 6000 7000
expand as a result of heat and cannot W hours
come into contact with inflammable
materials. W1 * * * * * * *

The compressed air line connected at the W2 * * * * * * *

air exit of the unit must not be under strain. W3 * * * * * * *
W4 Once a year or whenever a differential pressure of >1 bar occurs!
W5 Every 250 hours.
W6 Prior to each start-up!
W7 * * * * * * *
W8 Once a year or every 1000 hours!
* These maintenance intervals must be observed.
12 53
 9. Maintenance 3. Security Regulations

9.1 General maintenance Attention Compressed-air lines have to be marked Set up the machine in such a way that no
distinctly according to local regulations. inlets, outlets or gates are blocked, even
Clean the screw compressor at regular, not In addition to the maintenace charts when the doors are open.
If several compressors are arranged in a
too long intervals: of the KHD engine the following items of system, manually operated valves have to Before disconnecting the machine from
the engine operating instruction apply be installed so that each machine may be the towing vehicle, apply the handbrake.
* Blow-clean all valves, controllers,
after 50 operating hours after the start- shut off individually. For the purpose of Disconnect the rapid-emergency brake
fittings, pressure tank, oil cooler,
up of new or overhauled engines: shutting off pressurized systems, you cable and lighting cable, disconnect the
radiator, screw compressor, and engine
with compressed air or a steam jet * Check engine for leaks, repair if should never rely on the effectiveness of lines of the air brakes, use chocks to
appliance. necessary return valves alone. ensure that the machine does not roll away.

* Inspect the cooling ribs of the engine to * Change engine oil Safety devices, protective covers, or If a machine with a combustion engine
make sure that air can pass through insulations mounted on the system must has to work in a fire-risk environment, the
* Replace oil filter cartridge not be removed or modified in any way. unit must be fitted with a spark catcher.
* Clean the body at regular intervals. Then
* Changing the fuel filter cartridge All pressure tanks located outside the unit In dusty environments, set up the
grease or oil the hinges of the body
hood with multi-purpose grease. * Check tappet clearance, adjust if with an approved operating pressure higher machine in such a way that the wind does
necessary than atmospheric pressure and fitted with not blow dust in its direction. During
two or more pressure feed lines must be operation in clean environments, the
* Check engine mounts, tighten if equipped with an additional safety device intervals for cleaning the air intake filter
9.2 Engine maintenance necessary to automatically prevent the approved and the cooler elements are much longer.
* Check V-belt, tension if necessary operating pressure from being exceeded by
The maintenance of the engine is to be Do not install the machine directly in
more than 10%.
carried out in accordance with the engine front of walls. Make sure that the warm air
operating manual. Pipes and other parts with a surface coming from the engine and cooling
9.3 Maintenance of chassis and temperature of more than 80 °C must be systems is not drawn into the air intake
Danger suitably secured against contact and under any circumstances. Drawing this
brakes
suitably marked. warm air in through the engine or cooler
During inspection, adjustment, or fan could lead to overheating; if it is
The maintenance of the chassis and the Electrical connections must comply with
maintenance work, remember that the drawn into the combustion chamber, this
brakes must be carried out in accordance local regulations.
surfaces of machine parts can be hot, will result in a loss of power.
with the chassis instruction manual.
particularly the exhaust system (risk of With compressors fitted with generators,
burning) and that the control device may Work on the brakes may only be carried use equipotential bonding systems for the
move during operation (risk of out by trained technical staff or by specialist protection of persons.
crushing). brake services!
Install the machine so that it is as
Danger horizontal as possible; a slight inclination is
permissible (see information in Chapter
During inspection, adjustment and "Installation").
maintenance work, pay attention to
the hot surfaces of machine parts, in
particular the exhaust system (danger
of burns), as well as the regulating
device, if it is still moving (danger of
crushing).

52 13
 3. Security Regulations 8. Fuels

Never relocate the machine if external Before using the ether cold-starting 8.4 Diesel fuel
8.3 Tool lubricants
lines or hoses are connected to the system, please read the instructions
discharge valves, in order to avoid damage carefully. Use common diesel fuel with a sulfur
to the valves and/or collecting pipe and Attention
Never use the ether cold-starting system content of less than 0.5 %. If the sulfur
hoses. content is higher, oil has to be changed at
while the engine is running, as this can lead The wrong tool lubricants lead to
No force may be exerted on the to serious damage. deposits that cause malfunctions in the shorter intervals.
discharge valves, for example by pulling appliances connected! The following fuel specifications are
Wear suitable eye protection when
the hoses or fitting additional equipment applicable:
inspecting the system. Make sure that the For the perfect lubrication of concrete
(e.g. a water separator, compressed air
openings of containers, valves, or pipes are breakers and pneumatic spades, we * DIN 51 601
oiler, etc.) directly to the discharge valve.
never directed at yourself or at any other recommend the use of CompAir DEMAG * Nato Codes F 54, F 75, and F 76
Make sure that: person during inspection. oilers or automatic pipe oilers, using the * BS 2869: A1 and A2 (observe sulfur
special synthetic CompAir DEMAG oil content with A2)
* All bolted connections have been Never store ether containers at
AES 82. * ASTM D 975-81 : 1-D and 2-D
tightened temperatures above 70 °C.
The special advantages of CompAir * VV-F-800a : DF-A, DF-1, and DF-2.
* All electrical wiring has been connected
DEMAG oil are as follows:
correctly and is in good condition Normal operation Note
* Biodegradable,
* The engine exhaust system is Before starting work, make yourself See engine instruction manual.
operationally safe and that no familiar with the working environment at the * Ice guard down to -50 °C, for use with
inflammable material is in the vicinity installation site. The working environment sound absorbers, At low temperatures, paraffin precipitation
includes, for example, obstacles in the can cause blocks in the fuel system and
* The wheel nuts are properly tightened; * Very good lubricity, thus wear-reducing,
working and transport areas, the carrying disruptions in operation. Below outside
never exceed the specified torque. temperatures of 0 °C use winter diesel fuel
capacity of the ground, and any necessary * No irritating exhaust gases, work in
cordoning off of the building site from public enclosed rooms possible, (to -15 °C). (This is usually available at gas
traffic areas. stations in good time before the winter
Cold-starting diesel engines with ether * Good cleaning effect, no residue season begins.) Diesel fuel with additives is
fuel systems Take the necessary precautions to make formation frequently offered for use at temperatures
sure that the machine / installation is only as low as -20 °C („Superdiesel“).
The fuel used in these systems is highly * Excellent preservation properties,
operated in a safe, functional condition.
inflammable, toxic and poisonous. Avoid protects from corrosion.
contact with eyes and skin, and never Note
When using compressed air consumers
inhale vapors. Should you accidentally
made by other manufacturers, then their Only mix in the tank. First put in the
swallow fuel, do not induce vomiting, but
regulations must be observed. required quantity of petroleum, then fill up.
seek medical attention.
See engine instruction manual.
Below -15 °C or -20 °C, petroleum must
be added.
If it is necessary to use summer diesel
fuel below 0 °C, petroleum can also be
added up to 60 %.
In most cases, adequate resistance to
low temperatures can be achieved by
adding a product to improve flow properties
(fuel additive). Consult your engine service
station.
14 51
 8. Fuels 3. Security Regulations

8.1 Recommended lubricant for The viscosity of the lubricants should Only operate the machine when all Avoid any working methods that could be
comply with viscosity class ISO VG 32 DIN protective devices, shutdown devices, considered risky!
compressor
51519, July 1976, with 28 - 35 mm2/s(cSt) / sound-insulating equipment and extraction
Never play about with compressed air.
40 °C, or if the ambient temperature is equipment is in place and working.
Note constantly above 25 °C, with viscosity class Never direct compressed air onto the skin
Be careful: loose articles of clothing, hair
ISO VG 46 DIN 51519, July 1976, with or towards another person.
In these screw compressors, circulating oil or limbs can still be drawn in by revolving
41 - 50 mm2/s(cSt)/40 °C.
has not only a lubricating function, but in parts. Never use compressed air for cleaning
particular it also has cooling and sealing Attention clothing. When using compressed air to
Verify regularly that:
functions. It is therefore exposed to more clean equipment, work with extreme
difficult conditions. In particular the Conventional engine oils marked HD * All protective equipment is properly caution and always wear suitable eye
temperature conditions at the installation must not be used. positioned and fixed in place protection.
site and the consistency of the air (dust,
When using oils with the “Brief De- * All hoses and/or pipes within the system The compressed air produced by these
dirt, and humidity content, as well as
scription HYD 10/HYD 20" in accordance are in good condition, are properly fixed compressors must not be used as breath-
chemical influences) must be taken into
with the ‘Standard Lubricants for Building in place and do not chafe able air, unless it has been processed
account when selecting a suitable lubricant.
Machinery and Vehicles’ published by the specially for such an application in
* There are no leaks (fuel, oil or coolant
Attention ‘Hauptverband der Deutschen Bauindustrie accordance with the “Safety requirements
leaks)
e.V.’ (Principal Association of the German for breathable air.”
Do not mix oils of different Building Industry), only the given hydraulic * All bolted connections have been
When breathing apparatus with cartridges
specifications. fluids may be used in accordance with tightened
is used, make sure that the correct
ISO VG 32 and ISO VG 46. * All electrical wiring is properly connected cartridge has been inserted and that its
The maintenance intervals and the
maximum and minimum operating If other lubricants are to be used, please and is in perfect condition service life has not expired.
temperatures given in this operating contact: * Safety valves and other pressure-relief Never use the machine in environments
manual only apply when high-quality devices are in perfect condition and are where the possibility cannot be ruled out
CompAir Drucklufttechnik GmbH
multi-grade oils are used. not blocked, for example by dirt or paint that inflammable or toxic vapors may be
Argenthaler Straße 11
Use of the wrong oil leads to impairment D-55469 Simmern/Hunsrück taken in.
* The safety devices all work properly
of function. Telephone 06761 / 832-339 Never operate the system at temperatures
Telefax 06761 / 832-421 All connected components must be of
Out of consideration for the high loads and/or pressures below or above the values
the correct size and be suitable for the
imposed on the lubricant in screw or your authorized dealer or your local indicated in the technical data sheet.
specified operating pressure and
compressors with oil injection cooling, we branch. temperature.
recommend the use of suitable, non
ageing, non foaming, corrosion-protective Only use the correct type and size of
oils. They must meet the following hose coupling and connection.
8.2 Recommended engine oil
requirements for hydraulic fluids:
Before blowing through a hose or air line,
H-LP 32 and H-LP 46 in accordance with Lubricant specifications for the driving it is essential to hold the open end firmly.
DIN 51524, Part 2, June 1985. engine can be found in the enclosed engine If the open end is not held firmly, it can
operating manual. whiplash and cause damage or injury.

50 15
 3. Security Regulations 7. Putting the compressor into operation

Persons working in environments or The exhaust emissions of combustion 7.7 Shutdown 7.8 Decommissioning
rooms in which the acoustic pressure is engines contain carbon monoxide - a lethal
85 dB(A) or higher must wear ear muffs. gas. If a machine with such an engine has In order to shut down the compressor:
Caution: this may impair communication to work in an enclosed room, the exhaust
between persons. Warnings may not be gases must therefore be conducted out * Close air discharge valves. The screw
heard. Inform supervisor. of doors by means of a hose or pipe with compressor reduces the speed of the
an internal diameter of at least 100 mm. engine back to idling speed after the
Shieldings and doors must be closed preset final pressure has been reached.
The use of extraction systems is highly
during operation so that the flow of cool air
recommended in test rooms for mobile * Allow the screw compressor to idle for a
within the housing is not deflected and the
machines. few minutes.
efficiency of the sound-insulating is not
reduced. Doors and hoods may only be Before connecting or disconnecting * Turn the ignition key to the left, to the 0
opened briefly. hoses, always close the compressor air position; the “Battery charge” and “Fault”
outlet valves. Before disconnecting a hose, indicator lamps must go off.
With water-cooled combustion engines
always make sure that it is not under
with a closed cooling circuit, the cap of the * Withdraw the ignition key. Fig. 21
pressure.
coolant recovery bottle must not be
removed before the system has cooled A hose connected to an air valve must The screw compressor is automatically If the system is to be closed down for a
down to ambient temperature. be fitted with a safety wire for operating depressurized to atmospheric pressure. longer period of time (approx. 3 months
pressures above 7 bars; it is in fact or longer) the following preservation
Never fill up with fuel while the engine is measures must be taken:
recommended that this safety device
running. Make sure that fuel does not come
should be used for pressures above 4 bars. * Engine preservation (see separate
into contact with hot machine parts.
The steel wire has a diameter of 8 mm engine operating manual).
Do not smoke while filling up with fuel. and is firmly clamped to the hose at least
every 500 mm. Both ends are fitted with * Disconnect battery cables.
Filling up at a pump can cause static
cable lugs. * No special measures are required at the
electricity and possibly sparks. In order to
avoid this, a ground cable must be Check the machine / installation for compressor.
connected to the system while it is being external damage and faults at least once * Relieve the strain on tyres by jacking up
filled up. per shift. Any changes noticed (including the vehicle.
changes in operating performance) must be
reported immediately to the authority or * Check tyre pressure every 2 months.
person in charge. If necessary, shut down * Release the handbrake.
and secure the machine immediately.
In case of malfunction, shut down and Attention
secure the machine / installation
immediately. Have malfunctions corrected When putting back into operation, carry
immediately. out the maintenance work in accordance
with Chapter 9 “Maintenance.”
Observe the operating manual for start-up
and shutdown procedures as well as
inspection displays.

16 49
 7. Putting the compressor into operation 3. Security Regulations

Pressure gauge for display: 7.6 Operation 3.6 Special jobs / Maintenance For all work concerning the operation,
“Operating pressure” production adjustment, conversion, or
Care settings of the machine / installation and its
Danger safety-relevant equipment, as well as
Observe the setting, maintenance, and servicing, maintenance, and repair, observe
Only operate the compressor at the inspection work and intervals stipulated in
permissible operating pressure and at the operating manual for startup and
the operating manual, including information shutdown procedures and the instructions
the permissible temperature. about the replacement of parts / partial for maintenance work.
Only use the compressor for its sections. This work may only be carried out
intended purpose (see Chapter 1.2 of by specialists. All maintenance and repair work may only
this operating manual) in order to avoid be carried out when the system is shut
Maintenance work, tests and repairs down, or, with electrical systems, when the
residual risk for persons and assets. should be carried out in a well ventilated mains power supply is switched off. Make
Only operate the compressor in a safe, room, away from heat, open flames, or sure that the equipment cannot be switched
functioning condition. sparks. Appropriate prohibition signs (fire, on by accident.
open flames, no smoking) must be put up.
Fig. 20 All components, hoses etc. fitted must Whenever the machine/system is
be of the correct size and designed for Loss of oil leads to a very slippery floor. completely powered down for maintenance
Danger the specified operating pressure and Statistics have shown that many accidents and repair procedures, it has to be
temperature. can be attributed to the installation or secured against unintentional power-on
Do not operate the compressor at maintenance of machines on oily floors or or the mains supply has to be cut off
When working with compressed air, machine components. For this reason,
pressures above the permissible with electrical systems.
wear suitable protective clothing (e.g. always start maintenance work by cleaning
operating pressure.
protective suit, safety goggles, etc.). the floor and the machine exterior. * Remove the ignition key, and / or
The pressure gauge shows the operating
Wearing ear muffs may impair Inform operating personnel before * Put up a warning sign on the main
pressure of the compressor.
communication between persons. beginning to carry out special work or switch “Attention! Maintenance work.”
The permissible operating pressure is Warnings may not be heard. Inform maintenance. Nominate a supervisor. Close off the complete maintenance
indicated on the nameplate! The safety supervisor. area, if required.
valve pressure is indicated on the pressure After completing repair work, always
Check the compressor regularly. check to see whether any tools, loose * Disconnect the starter battery.
gauge by a red mark.
Leaking condensation contains a parts or cloths have been left in or on the Individual parts and larger subassemblies
Attention proportion of oil and must be collected machine, driving engine or driving must be carefully attached to the hoisting
and disposed of under safe conditions. equipment. gear and secured in case of replacement.
Do not operate the compressor above Condensation must not enter the
the permissible final compression Maintenance and repair work is only to be Only use suitable, technically perfect
soil or the rivers. Major quantities of carried out under the supervision of or by a
temperature. condensation accumulate particularly hoisting gear and load suspension devices
person qualified for this work. with adequate carrying capacity. Keep clear
The compression temperature is in versions with aftercoolers for
processing compressed air. Provide a of suspended loads.
measured by the temperature probe
(set point 115 °C). collecting basin. Before removing any part under pressure,
separate the aggregate effectively from
The compressor is automatically shut all sources of pressure and release the
down when the permissible final pressure from the complete system.
compression temperature is exceeded.

48 17
 3. Security Regulations 7. Putting the compressor into operation

Never use inflammable solvents or Maintenance 7.4 Setting the operating pressure This readjusted operating pressure is to
carbon tetrachloride to clean parts. be checked using the pressure gauge on
During maintenance and repair work, the
the instrument panel at 100% air discharge
Take precautions to avoid toxic vapors contractor has to inform the personnel
and maximum engine speed.
from cleaning fluids. about the dangers that can occur during
their work and about measures to avert
Absolute cleanliness is essential during
such dangers.
maintenance and when carrying out
repairs. The personnel have to support all
7.5 Monitoring
measures to improve safety at work.
Only carry out maintenance and repair
work when the machine is located on an Safety devices for preventing or Danger
even, stable base and is secured against eliminating dangers must be serviced
running away and against buckling. regularly and their functioning tested at Overriding the safety chain in this
least once per year. Faults discovered must automatic monitoring system is not
Only carry out inspection, maintenance, permissible. The display on the
be corrected at once or reported to the
and repair work when the screw compressor pressure gauge may not go further
supervisor. Fig. 19
system is at a standstill and is not under than the red line.
pressure. Only use the correct tools for
maintenance and repair work.
Danger When the “Fault” indicator lamp lights up,
Protective devices, i. e. protective grids, the screw compressor is automatically shut
may not be removed during operation. Only use original spare parts. The setting of the operating pressure
down when the following faults occur:
may only be carried out by a specialist.
Caution while the screw compressor is in All maintenance and repair work may only * Compressor temperature too high
operation. be carried out when the system is shut The screw compressor has been
down, or, with electrical systems, when the factory set to an operating pressure * Engine oil pressure too low
After the work has been completed, (final pressure) of 7 bars. The pressure
mains power supply is switched off. Make * Parting of a cable
replace any protective devices that have may be adjusted between the values of
sure that the aggregate cannot be switched
been removed. Operation without 5 and 8 bars, higher pressures are not * Engine temperature too high
on by accident.
protective devices is not permissible. permissible.
Whenever the machine/system is * Generator V-belt torn, or generator
Working clothing should be close-fitting Operating pressure is set by a specialist defective
completely powered down for maintenance
during work on running screw compressor at the controller.
and repair procedures, it has to be
systems. After one of these faults, it is only
secured against unintentional power-on * Remove knurled nut (counternut) below possible to restart the machine after the
or the mains supply has to be cut off the control knob of the regulator. fault that caused the machine to be shut
with electrical systems.
down has been corrected.
* Raise pressure by turning the adjusting
* Remove the ignition key, and / or knob of the regulator clockwise
* Put up a warning sign on the main (towards +).
switch “Attention! Maintenance work.” * Lower the pressure by turning the
Close off the complete maintenance adjusting knob of the regulator
area, if required. anticlockwise (towards -).
* Disconnect the starter battery. * In order to lower the pressure, open an
Before removing or opening any part air discharge valve.
under pressure, separate the equipment * After altering the pressure, lock the
effectively from all sources of pressure and adjusting knob using the knurled nut.
release the pressure from the complete
system.
18 47
 7. Putting the compressor into operation 3. Security Regulations

Start-up using jumper cables / auxiliary Cold-starting diesel engines with ether For moveable machines support the Wear suitable eye protection when
batteries fuel systems towing mechanism and axle with inspecting the system. Make sure that the
appropriate means if work is to be carried openings of spray containers, valves,
Attention out underneath the units (a jack is not pipes, or atomizers are never directed at
sufficient). yourself or at any other person during the
For cold starts (winter operation) inspection.
Startpilot or any other starting aid may Observe the safety precautions for work
be sprayed directly into the engine air on batteries. The fuel used in these systems is highly
filter (Attention: do not confuse this with inflammable, toxic and poisonous. Avoid
Pay attention to cleanliness. Prevent dirt
the air filter for the screw compressor). contact with eyes and skin, and never
from entering by sealing the parts and
(It is essential that the engine operating inhale vapors. Should you accidentally
exposed openings with a clean cloth,
manual be observed.) swallow fuel, do not induce vomiting, but
paper, or tape.
seek medical attention.
Never use the ether cold-starting aid Before the aggregate is approved for
while the engine is running, as this can Should fuel come into contact with the
operation after maintenance or an
lead to serious damage. eyes, or in case of eye irritation by vapors,
Fig. 18 overhaul, make sure that operating
flush eyes with plenty of clean water and
After starting, run the screw compressor pressures, temperatures, and time settings
seek medical attention.
Danger with the air cock half open until the engine are correct and that the control and
has reached its full load speed, then close shutdown devices are working properly. Every time a message is displayed or
Longer operation with an auxiliary the bleeder cock; the engine runs at idling there is a suspicion that an internal part
battery or jumper cables connected can The electric motor, generator, air filter,
speed. of the machine has overheated, the
lead to sudden emissions of gas. An electrical components and control
machine must be shut down. Never open
inflammable air / gas mixture is formed. Before using the ether cold-starting aid, equipment are to be protected against the
the inspection cover, however, before the
Explosion hazard! carefully read the instructions and the label penetration of dampness - for example
machine has cooled down sufficiently to
on the tank. when cleaning with a steam jet - by
rule out the possibility of the oil vapors
Attention covering or sealing them.
igniting spontaneously when mixed with air.
Danger Under no circumstances should the
Serious damage can be caused to the In order to avoid an increase in operating
Never store the ether tank at tempera- sound-insulating material be removed or
electrical system if wrongly connected. temperature, inspect and clean the heat
tures above 70 °C. modified.
transfer surfaces (cooling ribs etc.)
* Set ignition key to 0 position. Never use solvents with dangerous regularly. Draw up a schedule for the most
* First connect positive terminal then
Note properties for cleaning parts. suitable cleaning intervals for each
negative terminal (ground). machine.
Follow the instructions for operating the Maintenance work, tests, and repairs
* Start as described in section “Starting up compressor at an ambient temperature of should be carried out in a well ventilated
the compressor.” less than 0 °C, in Chapter 5, Transport and room, away from heat, open flames, or
Installation on Site, in this operating sparks. Appropriate prohibition signs (fire,
Note manual. open flames, no smoking) must be put up.

After the engine has started, first

disconnect the negative cable (ground)
and then the positive cable.

46 19
 3. Security Regulations 7. Putting the compressor into operation

Avoid damaging the safety valves and Machines whose main movement is back 7.3 Start-up Attention
other pressure-reducing devices. In and forth must be moved at least once,
particular, make sure that they are not rotating machines several times, in order to The machine may only be operated with
blocked through paint, oil carbon, or make sure that there is no mechanical
Danger
the hood closed. Otherwise cement and
dust accumulation, which could impair malfunction in the machine or in the driving Before starting up, make sure that no sand may enter the machine when the
the effect of these devices. part. one is in the danger area of the engine / hood is open, and this is bound to
The insulation or protective shielding of Only experienced persons may be screw compressor. cause serious faults.
parts whose temperature may exceed charged with slinging loads and instructing Compressors may not be operated in Opening the hood interferes with the
80 °C and which may accidentally be crane drivers. These instructors must hazardous environments unless they flow of cool air in the compressor
touched by personnel may not be removed remain within sight of the operator or be in have been specially designed for this section.
before these parts have cooled down to touch with him via walkie-talkie or similar purpose (e.g. exhaust protected against
room temperature. device. Full sound-insulating is only achieved
emission of flying sparks etc.). when the hood is closed.
Check the accuracy of the pressure During assembly work above body height, After service work has been completed:
and temperature displays regularly. If the use appropriate or otherwise safety- Check the oil levels in the pressure tank
Make sure that all protective devices and in the engine of the compressor
permissible tolerance limits have been relevant climbing aids and working have been refitted and that all tools have
exceeded, then they must be replaced. platforms. Do not use machine parts as each time before start-up.
been removed.
climbing aids! Wear safety belts when
Never carry out welding work or any other The exhaust emissions of combustion
carrying out maintenance work at greater Starting up the compressor:
work that produces heat in the vicinity of engines contain carbon monoxide - a
heights.
fuel or oil systems. Systems, which could lethal gas. If a machine with such an * Opening the shielding/hood interferes
contain fuel or oil, have to be completely Keep all steps, handles, railings, engine has to work in an enclosed room, with the flow of cool air in the
drained and cleaned, e.g. by means of a platforms, scaffolds, and ladders free of the exhaust gases must therefore be compressor section.
steam jet, before proceeding with the work dirt, snow, and ice. conducted out of doors by means of a
to be carried out. * Mount sound absorbers at the air
Before beginning maintenance and repair, pipe or hose with an internal diameter of
discharge valve.
Never carry out any welding work on any clean the machine, particularly couplings at least 100 mm. The use of extraction
pressure tank or components under and bolted connections, of oil, fuel, and systems is highly recommended in test * Half open the air discharge valve.
pressure, or modify them in any way. special care products. Do not use rooms for mobile machines.
* Insert the ignition key in the ignition and
aggressive detergents. Use lintfree cloths Only operate the compressor with the starting switch and turn to position I;
If work causing heat, flames, or sparks
for cleaning. hood closed. The hood may only be the indicator lamps “Battery charge” and
has to be carried out on a machine, the
surrounding components must be protected opened briefly for minor adjustments “Fault” come on.
with nonflammable material. while the compressor is running.
* Push in the ignition key slightly and turn
Before dismantling or overhauling a Skilled personnel only are authorized to further to position II; hold the ignition key
compressor, engine, or any other machine, work with the hood open. in position II until the engine starts
make sure that no movable part with a running and the “Battery charge” and
When working with the screw “Fault” indicator lamps go off.
weight of more than 15 kg can move or roll compressor in operation and with the
away. shielding/hood open, wear ear * Release the ignition key.
protection.
If the engine has not started after
Caution: this may impair communication 15 seconds at the latest, turn the ignition
between persons. Warnings may not be key back to the 0 position. As soon as the
heard. Inform supervisor. starter has reached a standstill and the
pressure tank is no longer under pressure,
the engine can be started again.

20 45
 7. Putting the compressor into operation 3. Security Regulations

7.1 Initial operation 7.2 Operating elements After cleaning, remove all covers and On charging a battery, an explosive gas
seals. mixture is formed in the cells, which can
Transport inspection Control elements on the instrument escape through the vent holes in the
After cleaning, check all fuel, engine oil,
housing: sealing caps. If ventilation is poor, a highly
Every CompAir DEMAG screw and hydraulic fluid lines for leaks, loose
explosive atmosphere can form around the
compressor has already run in the factory connections, chafing and damage. Correct
2 1 battery, and can persist for several hours
and has already undergone a thorough any faults immediately.
after charging.
test before shipment. This test ensures that Always tighten bolted connections
the compressor complies with the given Thus:
loosened during maintenance and repair
data and works perfectly. Independent of work. * Never smoke in the vicinity of batteries
the care taken in the factory, it is still that are being charged or have just been
possible for the compressor to be damaged If it is necessary to dismantle safety
charged.
during transport. For this reason it is devices during machine set-up,
recommended that the unit should be maintenance, and repair work, the safety * Put up prohibition signs for fire, open
examined for possible damage during devices must be reassembled and checked flames and smoking in workshops where
transport. 3 4 5 immediately after completing the batteries are charged.
maintenance and repair work.
During the first hours of operation, the * Never interrupt a current-carrying circuit
Fig. 17 Ensure safe, environment-friendly at battery terminals because of the
compressor should be observed in order
to be able to ascertain any possible 1 Pressure gauge for "Operating pressure" disposal of process materials as well as danger of spark formation.
malfunctions. display replaced parts. Components containing oil,
* Proceed particularly cautiously when
2 Operating hours counter for example fine separators, and oils must
connecting or disconnecting
3 "Battery charge" pilot lamp be disposed of. Oil must not enter the soil!
Transport safety locking of the towing reinforcement cables or quick-charge
4 "Fault" pilot lamp cable clamps.
arrangement
5 Combined ignition and starting switch
Safety precautions for work with When starting up using jumper cables or
Positions of the combined ignition and batteries auxiliary batteries, first connect the positive
starting switch: terminals and then the negative terminals.
Stop: 0 The fluid contained in batteries is diluted
After starting the engine, first disconnect
Voltage: I sulfuric acid which can cause blindness if
the negative terminal (ground cable) and
Start: II brought into contact with the eyes, or
only then the positive terminal. Disconnect
serious burns if brought into contact with
Transport safety locking the auxiliary battery after the starting
the skin. For this reason it is essential to
procedure in order to avoid the risk of the
work with the greatest of care when
release of gas (explosion hazard).
servicing batteries, e.g. when checking
battery charge, and to take all necessary
safety precautions.

Fig. 16 Always wear long-sleeved overalls, acid-

resistant gloves and safety goggles.
The towing arrangement is positioned
vertically in accordance with Figure 16.
The clamp must be released and the
spacer removed on initial use. The towing
arrangement can then be adjusted
according to the required trailer height and
locked with the clamp/ratchet (see here
Undercarriage Operating Instructions).
44 21
 3. Security Regulations 6. Preparing the compressor for operation

3.7 Instructions concerning Only use insulated tools. Proceed as follows: 6.4 Checking the air filter
particular hazards Keep an adequate distance between the * Open tank lid maintenance display
machine/unit and overhead power lines!
Electrical Energy * Fill up tank with commercially available
When working near overhead power lines,
branded diesel fuel, using a sieve (use
Only use original fuses with the specified equipment must not come near the power
summer or winter diesel fuel depending
amperage. lines! Danger! Find out about the safe
on outside temperatures)
distance to be observed!
In case of faults in the electrical power * Close tank tight with tank lid
supply, shut down the machine / installation After touching high-voltage lines:
immediately! * Close shielding.
* Do not leave the machine.
Work on electrical systems or equipment * Move the machine away from the Note
may only be carried out by a trained danger area.
electrician or by trained persons under the The fuel tank should always be filled up in
leadership and supervision of a trained * Warn outsiders not to come closer or good time. For outside temperatures below
electrician in accordance with the touch the machine. 0 °C, use only winter diesel fuel.
Fig. 15
standards of electrical engineering. * Make sure that the voltage is switched More information on fuel quality, see engine
off. When the red service sector in the
Machine and system parts where service, operating manual.
transparent part is fully visible, the air filter
maintenance, and repair work is being * Do not leave the machine until the line For outside temperatures below 0 °C, is due for maintenance. (See Chapter
carried out must be switched off load, if which has been touched or damaged, observe the operating manual of the engine Maintenance, air filter replacement.)
required by regulations. First check the has been switched off load! manufacturer for winter operation.
deenergized parts to make sure they are off
load, then connect to ground and short- When working with high-voltage You can reduce the occurrence of
circuit, and insulate neighbouring parts that assemblies, ground the supply cable after condensation in the fuel tank considerably
are under tension. voltage has been isolated, and short- by filling it up in good time. This also
circuit the components, e.g. capacitors, prevents downtimes and starting problems
The electrical equipment of a machine / with a ground rod! that can occur when the fuel tank is run
installation must be inspected / tested
dry.
regularly. Faults, such as loose con-
nections or overheated cables, must be
corrected immediately.
If work has to be carried out on live parts,
then call in a second person to operate the
emergency stop switch or master switch
with overvoltage release. Cordon off the
working area with a red-and-white safety
chain and a warning sign.

22 43
 6. Preparing the compressor for operation 3. Security Regulations

Attention The replacement battery should be Gas, dust, steam, smoke Noise
unfilled and only be preloaded
Only carry out welding, burning, and Sound-insulating equipment on the
After a short test run, the oil level must so that it has to be filled with battery
grinding work on the machine / installation machine / installation must be in operative
not be above or below the upper or acid. The battery and the acid should have
when this has been explicitly permitted, as position during operation.
lower dipstick marks. For oil specifi- a temperature of at least +10 °C.
there may be for example risk of fire and/or
cations, see engine instruction manual. Wear the prescribed personal ear muffs.
Proceed as follows: explosion.
Caution: this may impair communication
* Fill up with battery acid as far as the Prior to welding, burning and grinding between persons. Warnings may not be
base of the control insert remove any dirt and inflammable heard. Inform supervisor.
6.2 Battery substances from the machine/system
* Leave the battery to stand for some time The power of perception may become
and its environment and ensure proper
* Then shake it gently adversely affected by the noise and by
ventilation (danger of explosion)!
carrying ear protection. Warnings may,
* If required, top up with acid Only operate combustion engines in therefore, not be heard. Circumspect
* Tighten sealing caps properly ventilated rooms. Ensure behaviour by all concerned is necessary.
ventilation is adequate before starting up
* The battery is ready for use Noise, even when it is not very loud, can
in closed rooms.
* Leave for 1 hour make us nervous and irritated, and after a
Follow the local regulations applicable at longer period of time our nervous system
the respective site of installation. can suffer serious damage. For this reason
6.3 Filling up the fuel tank a separate machine room is preferable, in
order to keep the noise from the machines
Hydraulic and pneumatic systems out of the workshop.
Fig. 13 Work on hydraulic equipment may only Depending on the number of machines in
be carried out by persons with special a machine room, the noise generated can
Danger knowledge of and experience in hydraulics. be very loud. Depending on the level of
sound pressure in places where people are
When working with battery acid (electro- Check all lines, hoses, and bolted
present, the following precautions must be
lyte), wear acid-resistant goggles, connections regularly for leaks and visible
taken:
gloves and apron. damage. Repair any damage immediately.
It is essential that damaged parts should be Below 70 dB(A): No special measures
The gases released by the battery are required.
replaced! Spurting fluid can lead to injuries
explosive. Avoid sparks and open fires
and fires.
in the vicinity of the battery. Above 70 dB(A): Persons permanently
Before beginning repair work, relieve the present in the room must
Do not allow acids to come into contact Fig. 14 wear ear muffs.
pressure in system sections to be opened
with skin or clothing. Wear safety
and in pressure lines (hydraulic and
goggles. Danger Below 85 dB(A): For occasional visitors
compressed-air lines) in accordance with
who are only in the
Place no tools on the battery. the descriptions of the subassemblies.
Only fill up with fuel when the screw room briefly, no special
The battery is filled and charged. The compressor is at a standstill. Hydraulic and compressed-air lines protective measures are
battery is fastened with clamping strips. Cleanliness is essential! Spill no fuel! must be routed and fitted in accordance required.
with the regulations. Do not confuse the
The batteries used are ready to be Filling up at a pump can cause static
connections!
installed and ready for service. electricity and possibly sparks.
Replacement batteries should be of the The fittings, length, and quality of
same type as the batteries installed hoses must be in accordance with the
(low gassing). requirements.
42 23
 3. Security Regulations 6. Preparing the compressor for operation

Above 85 dB(A): Noisy room. There must Note 6.1 Checking oil levels Attention
be a warning sign at
every entrance pointing CompAir DEMAG accepts no responsibility 6.1.1 Checking the oil level in the After a short test run, the oil level
out that persons entering for any damage or injury caused by pressure tank must not be above or below the
the room - even if only noncompliance with these safety measures upper or lower dipstick marks. For oil
briefly - must wear ear or noncompliance with normal care and specifications, see recommended
muffs. caution during the handling, operation, lubricants, Chapter 8.1.
Above 95 dB(A): The warning signs at the maintenance or repair of this compressor,
entrances must be even if not expressly stated in this 6.1.2 Checking the oil level in the engine
supplemented by the operating manual.
recommendation that
even occasional visitors
must wear ear muffs.
2
Above 105 dB(A):Special ear protectors
adapted to the volume
and spectral composition 1
of the noise must be Fig. 11
available. A warning sign
to this effect must be put
Danger
up at every entrance. Only check the oil level when the engine
Make sure that sound propagated is at a standstill and the compressor is Fig. 12
through walls and frames does not cause not under pressure.
1 Dipstick
an excessive sound level in the The pressure tank may be under 2 Oil filler
surroundings. pressure and the oil may be hot.
Danger
Risk of scalding! Spill no oil!
Oils, Greases and Other Chemical Only check the oil level when the
Check for leaks. compressor engine is at a standstill.
Substances
Proceed as follows: Spill no oil! The oil may be hot. Risk
When handling oils, greases and other of scalding! Check for leaks.
chemical substances, observe the safety * Before checking the oil level in the
Proceed as follows:
regulations applicable for the product. engine and in the compressor ensure
that the vehicle is standing horizontally. * Ensure that the screw compressor is
Caution when handling process materials standing horizontally.
(risk of burning / scalding). * Ensure that the screw compressor has
been out of operation for some time. * Ensure that the screw compressor has
been out of operation for some time.
* Unscrew dipstick.
Potentially-explosive environments * Unscrew dipstick.
* The oil level should be within the marks
The operation of the compressor in areas * The oil level should be as near as
on the dipstick.
where there is a risk of explosion is strictly possible to the upper dipstick mark.
forbidden! (Exception: specially-made * Correct as required. * Correct as required.
compressors with the necessary technical * Check the seal on the dipstick and * Screw in dipstick.
modifications for use in such areas) replace if required.
* Close oil filler.
* Screw in dipstick and tighten firmly. * For oil specifications, see “Engine
24 Operating Manual”. 41
 5. Transport and installation on site 3. Security Regulations

Temperatures 3.8 Symbols and definitions

The compressor should be set up in a
frost-free area, where the intake air
temperature may range from min. -10 °C Carefully read the Operating
to max. +45 °C. Manual before machine set-up and
For operation at an altitude above maintenance.
1,000 m, the compressor and engine must
be adapted (modified design).

Note
Particularly in case of installation out of
doors and at night, observe fuel tempera-
ture. At temperatures below 0 °C, summer
diesel fuel tends to precipitate and block
the fuel filter. In this case use winter diesel
fuel.
Never attempt to operate the
machine without the safety device
mounted.

Do not inhale any compressed air

from the system.

40 25
 3. Security Regulations 5. Transport and installation on site

Never attempt to operate the Location Attention

machine with open or loose The complete system is to be set up in
shielding. such a way that it is easily accessible and Greater inclinations endanger the
that the required cooling is guaranteed. operating reliability of the screw
Never block the air intake. Ensure that the compressor.
entering of moisture and dirt together with When setting up the unit on ground that
the intake air is kept to a minimum. is not horizontal, or with a variable angle
The compressor is to be set up away (see operating instructions) please consult
from walls. CompAir DEMAG.
Set up the machine in such a way that
Attention no inlets, outlets or gates are blocked,
even when the doors are open. Before
The screw compressor is to be set up in
disconnecting the machine from the towing
such a way that no air reflection can
vehicle, apply the handbrake. Disconnect
Attention Hot surface. take place, i.e. neither waste air nor
contact-breaking cable and lighting cable,
exhaust emissions may be drawn in; the
uncouple air brake lines.
same applies to dangerous admixtures
to the air. Drawing this waste air in Secure wheels with chocks.
could lead to overheating and a loss of
power. Note
The compressor must be set up in as In dusty environments, set up the machine
horizontal a position as possible. Maximum in such a way that the wind does not blow
permissible inclination during operation: the dust in the direction of the machine.
* In direction of pull: 15 degrees During operation in clean environments,
* Backwards: 15 degrees the intervals for cleaning the air intake filter
* To the right and to the left: 15 degrees and the cooler elements are much longer.

Attention

Attention Pressurized part or No force may be exerted on the dis-

system. charge valves, for example by pulling
the hoses or fitting additional equipment
(e.g. a water separator, compressed air
oiler, etc.) directly at the discharge
valve.

Fig. 10

26 39
 5. Transport and installation on site 3. Security Regulations

Attention 5.3 Installation on site Lifting spot

Do not attempt to use a crane hook or

similar load suspension devices direct
on the lifting device to avoid damages to
A A A
the lifting device!
Use proper hoisting gears only such as
hoisting straps in compliance with DIN B B B
standard 61360 with proper lifting capaci-
ty for connecting the load suspension
device (e.g. crane) and the lifting device.
A = B = 1,5 m
Never lift up or lash down the unit using
the shieldings!
Fig. 9
Never relocate the machine if external
lines or hoses are connected to the Danger Attention Maintain specified tyre
discharge valves, in order to avoid pressure! (See Chapter
damage to the valves and/or collecting The air intake must be positioned in Foreword, specifications.)
pipe and hoses. such a way that loose personal clothing
cannot be drawn in.
When loading, the following points must be
observed:
* Secure the load suspension device or
the hoisting gear in the lifting device of
Make sure that the pressure pipe from
the compressor to the aftercooler or the
air system can expand as a result of
heat, and that it does not come into
1,5 BAR

the screw compressor. contact with inflammable materials.

* When hoisting the compressor, set up The air intake is to be designed in such
the hoisting gear in such a way that the a way that no dangerous admixtures
compressor, which must be set up (inflammable solvent vapors etc.,
horizontally, is lifted vertically. but also other dangerous or toxic
* Only relocate the compressor by itself. substances) can be taken in. This also
Attention Hot and harmful exhaust
applies to flying sparks.
* Raise and lower the compressor gas.
Pipes and other parts with a surface
carefully.
temperature of more than 80 °C must be
* After relocating, remove the load suitably secured against contact and
suspension device or the hoisting gear suitably marked.
from the lifting device.
The operation of the compressor in
* Tie down the compressor on the cargo areas where there is a risk of explosion
area of the means of transport. is strictly forbidden! (Exception:
* Only tie it down at towbar and wheel specially-made compressors with the
axles. necessary technical modifications for
use in such areas)
* When the chassis is being dismantled,
Please also note the safety instructions
the shieldings with machine group may
in Chapter 3 on the subject of
only be supported under the base frame.
installation on site.
38 27
 3. Security Regulations 5. Transport and installation on site

Do not step/stand on maintenance * For a braking trailer connect the contact- 5.2 Loading/Relocation
valve or other parts of the breaking cable to the towing vehicle.
pressurized system. Raise and secure the supporting device.
* Connect the electrical connecting cable
(option) between the vehicle and the
screw compressor.
* Check the lighting (tail lights, brake
lights, indicator lamps, and rear fog
lights).
* Check to make sure that the wheels are
properly tightened, the tyres are in a
roadworthy condition and the tyre
pressure is correct (danger of accidents).
Fig. 8
Emergency stop When parking the compressor, use the
support or the jockey wheel to secure the Danger
compressor in a horizontal position. Apply
the parking brake. Use chocks to ensure Only use hoisting gear (e.g. crane) with
that the machine does not roll away. appropriate lifting capacity for the loads
occurring!
Attention Only use the correct suspension gear!
Always keep a safe distance from the Keep clear of the swiveling range of the
edges of foundation ditches and hoisting gear!
embankments! Do not travel across
slopes transversely. Keep clear of suspended loads!

Make sure to check the torque after All loose parts that could fall down
50 kilometers following wheel mounting during hoisting must first be removed
and at regular intervals. or secured; pivoting parts, like doors,
towbars, etc. must be secured in such
Tighten wheel nuts or screws evenly in a way that they cannot move.
a diagonal sequence to the specified
torque using a torque wrench. Never leave the load suspended on the
hoisting gear. Acceleration or braking
of the means of transport must remain
within the approved limits.
Please also observe the safety
instructions in Chapter 3 on the subject
of loading.

28 37
 5. Transport and installation on site 3. Security Regulations

5.1 Transport Danger Attention Prior to starting any

maintenance work consult
The screw compressor may only be the operating and
transported on public roads if
maintenance instructions.
* The machine group (engine) is not
running,
* The pressure tank is not under
pressure,
* The shieldings are closed,
* The blocks are firmly hooked in place,
* Hoisted and secured support
(tail wheel),
Fig. 7 * The tyres and brakes are operationally
Replacing the trailer coupling ring safe and roadworthy,
The coupling arrangements which can be * The lighting is fully functional.
used: Never exceed the maximum towing
* Trailer coupling ring RD 40 speed! Danger! Observe national
regulations!
* Coupling 50 dia.
Please also observe the safety
* Coupling ring 68 x 42 dia. (only for instructions in Chapter 3 on the subject
France) of transporting.
A different coupling unit in the form of a Before transporting the compressor,
complete kit may be ordered, if necessary. check to make sure that the drawgear of
Replacing the trailer coupling ring is the towing vehicle and the drawbar eye or
permitted only if proper fitting is carried out trailer hitch ball connection are aligned
by an inspectorate for the sector covered exactly to each other.
by the Regulations Authorizing the Use of
Vehicles for Road Traffic (e.G. the TÜV - When transporting the screw compressor
Technical Inspectorate, DEKRA - German with a vehicle, the following points must be
Motor Vehicle Monitoring Association, etc.). observed:
The inspection station provides a fitting * The shieldings are closed.
certificate to be kept with the vehicle
documents. * The blocks are firmly hooked in place.
* The support(s) is(are) retracted and
locked in position (jockey wheel).
* Tow bar connected to the towing vehicle,
coupling cable connected to trailer.
* The drawbar is adjusted to the height of
the towing vehicle.

36 29
 4. Construction and functional description 4. Construction and functional description

4.5 Terminal Diagram DIN ISO 1724

2 13
8

3
4 Terminal Diagram DIN ISO 1724

Connector Circuit connector

white blue (54 G) rear fog lamp

black brown (58 R) right taillamp

yellow green (R) right indicator lamp

7 11 9 red red (54) right stoplamp

left stoplamp
green yellow (L) left indicator lamp

brown black (58 L) left taillamp

5
blue white (31) ground

105 580 74
Fig. 6
The terminal diagram is designed for a voltage of 12 Volts!
1 10 14 12

Fig. 3
1. Screw compressor 9. Fuel tank
2. Instrument panel 10. Battery
3. Pressure tank 11. Diesel engine
4. Oil cooler 12. Chassis
5. Oil filter (compressor) 13. Crane ring
6. Air filter (compressor) 14. Vehicle and chassis type identification
7. Air filter (engine) number
8. Taps

30 35
 4. Construction and functional description 4. Construction and functional description

4.4 Wiring Diagram - Basic Design F1 Fuse 8A 4.1 Construction Frame and chassis
F2 Fuse 16A
The complete compressor unit is
S1 Ignition switch F2 Fuse 16A Compressor and engine mounted on an easily movable single-axle
S2 Engine oil pressure trailer. The trailer is fitted with a parking
D1 Blocking diode The SC 70 D-1 is a mobile compressor
S3 Compressor temperature brake and a height-adjustable support.
unit. A single-stage, oil-flooded screw
S4 Motor temperature switch
H1 "Battery charge" pilot lamp compressor represents the main part of the
S5 Vee belt switch
H2 "Fault" pilot lamp system. The CompAir DEMAG screw
profile represents the state of the art. The Airflow
Y1 Solenoid actuator
Y2 Solenoid valve P1 Op. hours counter air is delivered pulsation-free. Fresh air is taken in through the
The maximum operating gauge pressure generously sized inlet opening in the floor..
G1 Three-phase generator K1 Relay change-over contact is 7.0 bar. An air-cooled diesel engine The air intake volume is intake air for the
G2 Battery K2 Relay change-over contact driving the screw-type compressor rotor via engine and the compressor and at the
K3 Relay change-over contact a flexible flange coupling and a spur gear same time cooling air for the radiator and
M1 Starter K4 Relay change-over contact serves as the drive unit. the compressor oil cooler.
Bulkhead walls in the compressor are
provided to form channels. They optimize
Shielding (Body) the cooling air flow and reliably exclude a
The casing consists of a box mounted on thermal short.
a base frame. The swing-out hatches for
servicing are fitted to it. The lug protruding
through the roof is for suspension from
lifting tackle. The machine unit is
supported by rubber elements to reduce
vibration and prevent structure-born noise.
The control panel contains the ignition
starter switch as well as an operating hour
counter, a pressure gauge, fault and charge
indicator lights.
For convenient assembly, all individual
parts of the body are bolted together using
machine bolts. For effective corrosion
prevention, the individual parts are zinc-
phosphate coated, electrostatically powder
coated, and stove-enamelled at 220 °C.
All current noise regulations (15. Blm SchV,
ISO, EC directives) are complied with.
Besides an operating hours counter,
pressure gauge, fault indicator lamp,
battery charge indicator lamp, the
instrument panel also includes the ignition
switch for starting the compressor.
Fig. 5 131 030 74
34 31
 4. Construction and functional description 4. Construction and functional description

4.2 Functional description Regulation 4.3 System description 16. Oil filter
17. Oil cooler
A combined choke/speed regulation unit
Oil circuit 1. Air filter 18. Remote thermometer
allows continuously variable quantities of
2. Intake control valve 19. Temperature switch
The oil required for sealing and cooling air between 0% and 100% to be removed.
3. P-controller 20. Compressor
the rotors as well as for lubricating the roller On starting, the engine is placed under 21. Diesel engine
4. Relief valve
bearings is injected into the compressor full load. The intake control valve opens 22. Control cylinder
5. Nozzle controller
from the pressure tank, which is under through the resulting suction vacuum and Oil temperature controller option
6. Pressure gauge
system pressure. The difference in the compressor begins to transport air. 23. Oil temperature controller
7. Pressure limiting valve
pressure between the pressure tank and After operating pressure has been reached, 8. Tap
the oil injection position is approx. 1 bar. the controller causes the pneumatic engine 9. Venturi nozzle
The oil hereby passes the oil filter, the oil control cylinder and the intake control valve 10. Safety valve
cooler and the orifice. The optimum to be pressurized with control air. This 11. Pressure tank
delivery volume for each system type is causes the system to be limited to idling 12. Fine separator
ensured by throttling in orifice. The intake speed. The pressure limiting valve blows off 13. Sieve
control valve is fitted with a non-return the minimum amount of air transported 14. Orifice, evacuation line
function, so that when the system is during idling. After the system has been
switched off, flooding of the air filter is switched off, the solenoid valve opens and
prevented. the compressor is automatically vented.

Air circuit
The intake air flows through the air filter
and the suction control valve into the
compressor. During compression, oil is
injected in order to lubricate, cool and seal
the screw rotors. The compressed oil/air
mixture flows into the pressure tank where
the oil is preseparated.
Any remaining oil is separated from the
air in the fine separator.
The practically oil-free compressed air
then reaches the air discharge via a
pressure-retaining device. The pressure-
retaining device effectively prevents the
system pressure from falling below the
minimum operating pressure required for
the system to work properly. A temperature
monitoring device as well as an operational
pressure manometer are integral parts of
the air circuit.

Fig. 4 131 599 74

32 33